DE102018208407A1 - Method for producing stranded wire, method for producing an electric motor, and use of stranded wire - Google Patents

Abstract

The present invention relates to a method for producing a shaped strand (F) from a straight or substantially straight tapered insulated wire (1), characterized by the following process steps: a) forming the insulated wire (1) in at least one half-loop, ring or coil with b) twisting the at least one half loop, ring or helix into a wire package (D) with a twisting device (4), c) compacting the wire package (D) with a compacting device (5), and a method for Production of an electric motor, wherein the production of at least a portion of the stranded wire for the electric motor according to the method according to the invention takes place, and- the use of stranded wire in the stator (S) of an electric motor, wherein the stranded wire is at least partially the stranded wire produced according to the invention ,

Description

The present invention relates to a method for producing shaped wires according to claim 1, a method for producing an electric motor according to claim 10, and the use of a shaped strand according to claim 11 and a stranded wire according to claim 12.

Formed strands are strands, i. twisted or untwisted wire tufts, which are compacted and thus obtain a certain cross-sectional shape, usually a rectangular cross-sectional shape.

Formed strands can be used as segment conductors in electrical machines, in particular in stators. Segment conductors are conductor sections which are inserted or pulled in stator slots, for example. The protruding ends of two shaped strands can then be connected directly to half coils. The half-coils are also connected by correspondingly connecting on the opposite side of the stator. In this case, different winding patterns can be realized, for example, a concentrated winding or - of particular interest - a wave winding. Wave winding means that ultimately (three) continuous conductor strands meander around the stator slots. In a three-phase machine this is for example from the US9035526B2 or DE10113831 B4 known.

As a wire for shaped strands is preferably insulated wire, in particular enameled wire in question.

In the end sections (Formlitzköpfe) the individual wires are electrically and mechanically connected for the purpose of further contacting. This is done e.g. with ultrasonic or electrode welding, usually a sleeve is used for this purpose. The insulating lacquer of the wires, which is present in the shaped litz head, is always partly burned, partly squeezed out.

The connection of two Formlitzen can be done directly, eg by welding two Formlitzköpfe. The Formlitzköpfe are verhülst for this purpose, especially pressed or welded with a sleeve. This is for two reasons, on the one hand to create a defined bonding surface for the welding, on the other hand to electrically and mechanically connect the wire ends in the Formlitzkopf together. Examples of this are eg in the EP3051669A1 specified.

A disadvantage is the high complexity of a production plant, e.g. Stranding plants, which produces a shaped strand or a Formlitzrohling.

This is where the present invention sets out and makes it its task to propose an improved method for producing a stranded wire, in particular to propose a method which overcomes the aforementioned drawbacks, preferably to propose a method for producing a shaped strand which provides a secure electrical and mechanical connection allows the individual wires in a Formlitzkopf with each other and optionally with a sleeve.

The above object is achieved by a method according to claim 1. Further features and details of the invention will become apparent from the dependent claims, the description and the drawings. In this case, features and details described in connection with the method are of course also in connection with the described devices and vice versa, so that with respect to the disclosure of the individual aspects of the invention always reciprocal reference is or can be.

An insulated wire, which is usually supplied from a roll, is first converted into a forming device into at least one half-loop, ring or helix. Only one wire can be used. A synchronization of a plurality of wires deleted. Furthermore, can be dispensed with a complex stranding. In principle, the step of cutting or cutting off the end of the shaped strand can also be dispensed with. After the wire sections in the head are to be electrically connected anyway, the present in the head loops are not hindering, but even beneficial. After forming, the helix or the at least one ring or half loop can be twisted and compacted accordingly. The compacting is preferably carried out in a compacting device, wherein the twisted wire package is pressed in a compacting process to the stranded wire with a defined outer contour. The electrical and mechanical connection of the individual wires of the shaped strand in the head region can then be carried out using a method known from the prior art, optionally with the use of sleeves.

Further advantageous embodiments of the proposed invention will become apparent in particular from the features of the dependent claims. The objects or features of the various claims can basically be combined with each other arbitrarily.

In an advantageous embodiment of the invention can be provided that the forming is carried out in a configured as a winding holder forming device. A winding holder usually has two or four parallel arranged fingers on and is designed with or without rotation axis. In the manner of a reel, wire can be wound there or pushed on and shaped. Such a configuration is particularly suitable for forming the wire in at least one ring or a helix, wherein the shape depends essentially on the spacing and design of the fingers, but should basically approach a rectangle with preferably rounded corners, especially since this structure in a subsequent Process step is to be twisted to form an elongated stranded wire. In this respect, arise for the coil, but also for the ring, essentially two long sides and two short sides. An embodiment with only one finger is also conceivable, which is essentially suitable for converting a wire there to a half loop. In this case, correspondingly two long sides and a short side connecting the two long sides result.

A disadvantage was also recognized that the attached to the single wire insulation layer is a hindrance to the connection process of the individual wires in the Formlitzkopf and also obstructive due to paint residues for the connection process of two Formlitzköpfe, especially due to smoke, leakage of insulation residues from the Formlitzkopf , unsafe connection due to undefined quantity and distribution of insulation residues in the molding head etc.

In particular, the locally limited evaporation of the insulating varnish of the individual wires for both individual production (batch production) and continuous production (as endless wire) has been proposed. The problem here is the synchronization of the individual wires, so that the locally stripped portions of the individual wires come to lie flush on top of each other.

In an advantageous embodiment of the invention, a partial stripping of the wire or the half-loop, ring or coil takes place with a Abisoliereinrichtung, wherein the partial stripping after forming and before twisting, in particular on the long sides or on the short sides between fingers of a winding holder made or the partial stripping before forming, in particular on the straight or substantially straight tapered insulated wire is made. In the first variant, the partial stripping is performed at a time at which the shape of the at least one half-loop, ring or coil to be twisted is already fixed. In this respect, it can be ensured in a simple manner that the stripped areas are in the right places, namely at the points at which the individual wires are to make an electrical connection with each other and optionally with a sleeve. Alternatively, however, partial stripping may also be carried out prior to forming, in particular on the straight or substantially straight tapered insulated wire.

The partial stripping can preferably mechanical and / or abrasive, in particular by grinding and / or sandblasting, and / or chemical and / or thermal, in particular using cold brittleness, laser sublimation, induction heating takes place. This selection is not exhaustive. However, the aforementioned methods are particularly suitable for industrial use.

In a further advantageous embodiment of the invention can be provided that the twisting of the at least one half-loop, ring or coil is carried out with a twisting device, wherein the twisting device in particular a first gripper for the first distal end of the at least one half-loop, ring or coil, and in particular a second gripper for the second distal end of the at least one half-loop, ring or coil, wherein the grippers are rotated in particular about or about the longitudinal axis of the at least one half-loop, ring or coil.

In a further advantageous embodiment of the invention can be provided that the first gripper are formed by a first finger and the second gripper by a second finger or a pliers tool. Such a configuration of the twisting device is preferably suitable for twisting a half-loop. In particular, the open part of the half-loop can be gripped by the pliers tool while the closed part can be gripped by the finger.

In a further advantageous embodiment of the invention can be provided that the twisting device is integrated into the forming device or the twisting is performed in the forming device. This measure is used for process optimization, such that transfers of the at least one half loop, ring or coil can be avoided. In this context, it may be provided, for example, that the shaping device, in particular the winding holder, is equipped with appropriate mechanism that the fingers can be pivoted so that the at least one half-loop, ring or coil recorded on the fingers anyway can be twisted.

In a further advantageous embodiment of the invention can be provided that the insulated wire and / or the wire package is at least partially applied with a baked enamel. The baked enamel can mechanically fix individual wires against each other. This particularly applies to vibrations that occur when alternating current flows.

In a further advantageous embodiment of the invention, the mechanical and electrical connection of the wire sections takes place in the head ends without sleeves.

Another object of the present invention is to propose an improved method of manufacturing an electric motor.

According to the invention this object is achieved by a method according to claim 10. Because the stranded wire used there has been produced according to the method according to the invention, the advantages achieved there can be utilized for the construction of electric motors.

Another object of the present invention is to demonstrate an advantageous use of the stranded wire produced according to the invention.

According to the invention this object is achieved by a use according to claim 11. Preferably, the stranded wire produced according to the invention can be used in the rotor or stator of an electric motor.

Another object of the present invention is to propose an improved stranded wire.

According to the invention this object is achieved by a stranded wire with the characterizing features of claim 12.

• 1 eine gemäß dem erfindungsgemäßen Verfahren hergestellte Formlitze;
• 2 ein Stator eines Elektromotors, insbesondere eines elektrischen Traktionsmotors, z.B. für ein Automobil, mit einer mit dem erfindungsgemäßen Verfahren hergestellten Formlitze in einer seitlichen Ansicht;
• 3 ein Stator eines Elektromotors, insbesondere eines elektrischen Traktionsmotors, z.B. für ein Automobil, mit einer mit dem erfindungsgemäßen Verfahren hergestellten Formlitze in einer stirnseitigen Ansicht;
• 4.1 Umformen eines isolierten Drahtes in eine Wendel auf einem Wicklungshalter mit zwei Fingern;
• 4.1a eine Draufsicht auf den Wicklungshalter gemäß 4.1;
• 4.2 partielles Abisolieren des Drahtes auf dem Wicklungshalter gemäß 4.1/4.1a;
• 4.3 Verdrillen des Drahtes auf dem Wicklungshalter / Verdrilleinrichtung;
• 5.1 Umformen eines isolierten Drahtes in eine Wendel auf einem Wicklungshalter mit vier Fingern;
• 5.1a eine Draufsicht auf den Wicklungshalter gemäß 5.1;
• 5.2 partielles Abisolieren der Wendel auf dem Wicklungshalter gemäß 5.1/5.1a;
• 5.3/5.4 Übernahme der Wendel von dem Vierfinger-Wicklungshalter auf einen Zweifinger -Wicklungshalter;
• 5.5 Verdrillen der Wendel auf dem Wicklungshalter / Verdrilleinrichtung
• 6.1 partielles Abisolieren des isolierten Drahtes vor dem Umformen auf einem Wicklungshalter - Umformen eines partiell abisolierten Drahtes in eine Wendel auf einem Wicklungshalter mit zwei Fingern;
• 6.1a eine Draufsicht auf den Wicklungshalter gemäß 6.1;
• 6.2 Verdrillen der Wendel auf dem Wicklungshalter / Verdrilleinrichtung;
• 7 ein Wicklungshalter mit einem Finger und einer Halbschlaufe (Draufsicht / seitliche Ansicht);
• 8 ein Wicklungshalter mit zwei Fingern und einem Ring (Draufsicht / seitliche Ansicht);
• 9 eine Verdrilleinrichtung mit einem Finger, einem Zangenwerkzeug und einer Halbschlaufe;
• 10.1 - 10.5 Kompaktieren des verdrillten Drahtpaketes in einer Presse;
• 11 Elektrodenschweißen der Kopfenden der Formlitze zum elektrischen und mechanischen Verbinden der dort liegenden Drahtabschnitte.

Further features and advantages of the present invention will become apparent from the following description of preferred embodiments with reference to the accompanying drawings. Show in it

• 1 a molded strand produced according to the method of the invention;
• 2 a stator of an electric motor, in particular of an electric traction motor, for example for an automobile, with a formed strand produced by the method according to the invention in a lateral view;
• 3 a stator of an electric motor, in particular of an electric traction motor, for example for an automobile, with a formed strand produced by the method according to the invention in an end view;
• 4.1 Forming an insulated wire into a coil on a two-finger winding holder;
• 4.1a a plan view of the winding holder according to 4.1 ;
• 4.2 partial stripping of the wire on the winding holder according to 4.1 / 4.1a ;
• 4.3 Twisting the wire on the winding holder / twisting device;
• 5.1 Forming an insulated wire into a coil on a four finger winding holder;
• 5.1a a plan view of the winding holder according to 5.1 ;
• 5.2 partial stripping of the coil on the winding holder according to 5.1 / 5.1a ;
• 5.3 / 5.4 Takeover of the coil from the four-finger coil holder to a two-finger coil holder;
• 5.5 Twisting the coil on the coil holder / twisting device
• 6.1 partially stripping the insulated wire prior to forming on a coil holder - forming a partially stripped wire into a coil on a two-finger coil holder;
• 6.1a a plan view of the winding holder according to 6.1 ;
• 6.2 Twisting the coil on the coil holder / twisting device;
• 7 a winding holder with a finger and a half-loop (top view / side view);
• 8th a winding holder with two fingers and a ring (top view / side view);
• 9 a twisting device with a finger, a pliers tool and a half-loop;
• 10.1 - 10.5 Compacting the twisted wire package in a press;
• 11 Electrode welding of the head ends of the stranded wire for the electrical and mechanical connection of the wire sections lying there.

Starting point of a method according to the invention for the production of stranded wire is an insulated wire 1 , preferably a lacquer-insulated wire. This is an electrically conductive wire, preferably made of copper, aluminum or copper and / or aluminum alloys. The insulated wire can also have a further envelope, for example in the form of baked enamel. The insulated wire is usually on a roll, from which the wire is unrolled and supplied to the manufacturing process as a straight or substantially straight tapered wire. By this is meant that the wire is unwound from a roll and is transformed into the intended shape of the half-loop, ring or coil only in the forming process.

Result of the manufacturing process is a stranded wire F , The stranded wire comprises a first head end and a second head end. The head ends of the stranded wire (more precisely, the wire sections located there) are electrically and mechanically interconnected, with the aid of sleeves H1 respectively. H2 can be done. Between the head ends is a wire package D arranged. The wire package consists of a number of wires, which are usually twisted together and are preferably surrounded by a main insulation layer as a wire package. The shaped strand is also compacted and preferably has a rectangular or trapezoidal cross-sectional area.

• - Umformung eines isolierten Drahtes in mindestens eine Halbschlaufe, Ring oder Wendel auf einer Umformeinrichtung 2
• - optional ein partielles Abisolieren der mindestens einen Halbschlaufe, Ring oder Wendel mit einer Abisoliereinrichtung 3
• - Verdrillen der partiell abisolierten mindestens einen Halbschlaufe, Ring oder Wendel in ein Drahtpaket mit einer Verdrilleinrichtung 4
• - Kompaktieren des Drahtpaketes mit einer Kompaktiereinrichtung 5

A method according to the invention for producing formed strand comprises at least the process steps

• - Forming an insulated wire in at least one half-loop, ring or coil on a forming device 2
• - Optionally, a partial stripping the at least one half-loop, ring or coil with a Abisoliereinrichtung 3
• - Twisting the partially stripped at least one half-loop, ring or coil in a wire package with a twisting device 4
• - Compacting the wire package with a compactor 5

Under helix is to be understood a spiral-shaped structure with several turns. The ends are usually not connected to each other. In principle, however, it is possible to connect the ends of the helix. The helix does not necessarily have to be circular, but the helix has a more rectangular shape with rounded corners. In this respect can of two long sides 2a and two short sides 2 B the helix are spoken.

Under ring should be a self-contained structure of a wire with the number of turns 1 be understood, that is the ends are connected to each other. The ring does not necessarily have to be circular, but the ring has a more rectangular shape with rounded corners. In this respect can of two long sides 2a and two short sides 2 B to be spoken of the ring.

Half-loop is intended to mean a unilaterally open, U-shaped structure. The wire does not describe a complete turn and the ends are not connected. In this respect can of two long sides 2a and a short side 2 B the half-loop are spoken.

For the individual process steps, the following is stated:

reshape

The forming takes place in a forming device 2 , As a forming device so-called coil holder come into question.

In a simplest embodiment, the winding holder has a finger 2.1 over which the insulated wire is placed in a sense and transformed into a half-loop. Several wires can be placed behind one another on the finger and converted into several half loops. The resulting half loops can rest side by side and / or one above the other on the finger.

In a further embodiment, the winding holder can be two fingers 2.1 . 2.2 respectively. The two fingers are parallel or substantially parallel to each other and spaced from each other. One or more rings of the insulated wire can be pushed onto the winding holder. The rings can rest side by side and / or one above the other on the fingers.

In a further embodiment, the winding holder can be two fingers 2.1 . 2.2 and a rotation axis R respectively. The axis of rotation is preferably arranged between the fingers and parallel to the fingers. Essentially, this is a kind of reel on which the insulated wire can be wound into a helix. The wires of the helix can be arranged next to one another and / or one above the other.

In another embodiment, the winding holder may have four fingers 2.1 to 2.4 respectively. The four fingers are parallel or substantially parallel to each other aligned and spaced from each other. In a plan view, the four fingers preferably form the corners of a square or square. One or more rings of the insulated wire can be pushed onto the winding holder. The rings can rest side by side and / or one above the other on the fingers.

In another embodiment, the winding holder may have four fingers 2.1 to 2.4 and a rotation axis R respectively. The four fingers are parallel or substantially parallel to each other and spaced from each other. In a plan view, the four fingers preferably form the corners of a square or square. The axis of rotation is preferably arranged between the fingers, so to speak in the middle of the rectangle or square and parallel to the fingers. Essentially, this is a kind of reel on which the insulated wire can be wound into a helix. The wires of the helix can be arranged next to one another and / or one above the other.

Basically, a variant with three or more fingers in question.

The result of the forming process is the forming of an insulated wire into at least one half-loop, ring or coil.

stripping

The partial stripping of the at least one half loop, ring or helix takes place with a stripping device 3 , The partial stripping of the insulated at least one half-loop, ring or helix can be effected mechanically or abrasive, in particular by grinding and / or sand blasting. Also, chemical and / or thermal processes, in particular using cold brittleness, laser sublimation, induction heating, etc. are conceivable. In principle, any method which makes it possible to remove the insulation of the wire is conceivable here. By partial stripping is meant that a longitudinally extending portion of the insulated wire is stripped of the insulating material, which is intended to mean "relief" in technically relevant categories. If the insulated wire is still coated with other components, such as baked enamel, this component is also removed. Essentially, it is important that an electrically conductive surface of the wire is exposed.

The insulated wire 1 is basically still on the respective forming device 2 held, so that stripping in principle at those portions of the at least one half-loop, ring or coil in question, which are exposed, or in other words, are not in contact with a finger. Depending on the forming device here are preferred sections that are to be stripped or can.

In the case of the winding holder with a finger, the area of the half-loop next to the finger and at the end of the half-loop comes into question.

In the case of the winding holder with two fingers, the areas of the helix or of the rings are directly next to the fingers in question. In a sense, the ends of the long sides 2a stripped.

In the case of the winding holder with four fingers, the areas of the helix or the rings between two fingers come into question, preferably on the shorter sections of the helix or the rings, for example, when the fingers form the corners of a rectangle. In a sense, the short sides are stripped.

The result of the stripping process is a helix or rings or half loops with partially stripped wires.

twist

The twisting of the helix or of the rings or half loops takes place via a twisting device 4 , In essence, the twisting device comprises a first gripper 4.1 for the first distal end of the coil or the rings or half loops, and a second gripper 4.2 for the second distal end of the coil or rings or half loops. The grippers are twisted approximately around the longitudinal axis of the helix or the rings or half loops, so that the wires are twisted.

In a first embodiment of the twisting device, the first gripper is formed by a finger and the second gripper by a pliers tool. This twisting device is preferably suitable for twisting half loops. The pliers tool grips the free ends of the half loops while the finger grips the short sides of the half loops. In that regard, the first finger of the twisting device may also be the first finger of the forming device. The forming device can be equipped in this case with an additional mechanism that allows rotation of the finger and pliers tool against each other.

In a preferred embodiment of the twisting device, the first gripper is formed by a first finger and the second gripper by a second finger. This twisting device is preferably suitable for twisting the helix or the rings. The fingers grasp the respective distal spiral ends or ring ends, that is the short sides. In that regard, the first finger of the twisting device may also be the first finger or the second finger of the twisting device the second finger of the forming device. The forming device can be equipped in this case with an additional mechanism that allows rotation of the fingers against each other.

As far as the forming device is equipped with four fingers, the on wound coils or the helix are passed to a twisting device with two fingers. The twisting is then preferably done with this twisting device. Reference may be made to the statements made above.

The result of the twisting process is a twisted wire package.

compacting

The compacting takes place in a compacting device 5 , in particular a press.

The twisted wire package becomes a stranded wire in a compacting process F pressed. The preceding method steps ensure that the respective distal ends of the twisted wire package are stripped. If the ends still contain partially insulated wire, they may, but not necessarily, be cut off.
The result of the compacting process is a form strand F ,

The end sections of the shaped strands can then be electrically and mechanically connected to one another in a further process step 11 shows an electrode welding process with two welding electrodes e in which the wire sections of the head ends are electrically and mechanically interconnected. A sleeve is not absolutely necessary in the case of already stripped head sections.

Alternatively process

In the process outlined above, it is preferably provided that the forming is carried out before the stripping. In an alternative embodiment of the method can be provided that the stripping is carried out before forming (see in particular the 6 and 7 ). Otherwise, reference may essentially be made to the features already outlined above.

Here, an insulated wire, which is preferably fed from a roll, initially stripped partially with a Abisoliereinrichtung to be subsequently formed with a forming device to at least one half-loop, ring or coil. Preferably comes as a forming device, a rotatable two-finger coil holder in question. The synchronization of stripping to winding holder is preferably such that the stripped areas of the wire rest in the area of the fingers. As far as the forming device is further configured as a twisting device, the resulting at least one ring or coil can remain on the fingers and be twisted directly.

The result here too is a twisted wire package which can be supplied to the subsequent method step, in particular compacting.

The production process for the production of shaped wire from insulated wire is preferably carried out as follows (cf. 4 and 10 ).

Insulated wire is mounted on a two-finger winding holder with rotation axis R wound as Umformeirichtung to a helix. The wires of the coil are preferably all side by side.

By laser as Abisoliereinrichtung sections of the coil are immediately released next to the fingers of the insulation.

The shaping device likewise comprises the twisting device, so that the wire wound up between the fingers, that is to say the helix, can be directly twisted.

The wire package is inserted into the compacting device together with sleeves and pressed.

The result is a shaped strand with a predetermined by the shape of the press cross-sectional shape. The end sections of the shaped strands are then connected to one another electrically and mechanically by electrode welding. There is correspondingly an electrical contact between the stripped in this area ends of the wire package.

A further preferred production process for the production of shaped wire from insulated wire can be carried out as follows (cf. 5 and 10 ).

Insulated wire is mounted on a four-finger winding holder with rotation axis R wound as Umformeirichtung to a helix. The wires of the coil are preferably all side by side.

By laser as Abisoliereinrichtung sections of the coil are immediately released between two fingers of the insulation. In a sense, the short sides are freed from isolation.

The helix is transferred from the four-finger winding holder to a two-finger twisting device.

The helix is twisted into a wire package in the two-finger twisting device.

The wire package is inserted into the compacting device and pressed. Subsequently the end sections of the shaped strands are electrically and mechanically interconnected by electrode welding.

Additional Process Steps / Further Aspects of the Invention

Additional, but not exhaustive, process steps may be, for example, a baked enamel application or application of a main insulation layer around the formed strand, e.g. by extruding.

The baked enamel has the task of mechanically fixing the individual wires against each other. This particularly applies to vibrations that occur when alternating current flows. During heating and / or pressing, the baked enamel becomes viscous and glues the individual wire layers together, cf. for example DE102015201711A1 , Instead of a double layer (insulation + baked enamel), a combination material known to the person skilled in the art may also be used. The partial removal of the baked enamel should also fall under the production step "partial stripping".

It is also possible to produce shaped wires of a higher order. This means that strands with strands are twisted into a new (higher order) strand. This can be done within the process step "twisting".

Preferably, the forming device, Abisoliereinrichtung and / or twisting device are combined in one device. In particular, the fingers can have different functions (winding, twisting, ...). Of course, the facilities can also be configured separately.

The embodiments are generally not limited to the production of shaped strands with sleeves. The designs can also be applied to shaped strands without sleeves.

As already stated above, the stranded wire produced according to the invention is advantageously suitable for producing an electric motor, in particular its stator S , Accordingly, the advantages of the invention Formlitzeherstellungsverfahrens for the production of an electric motor, in particular its stator, can be exploited. In the 1 to 3 is an example of a stator S an electric motor shown.

In this respect, the use of inventively produced stranded wire in the stator offers S an electric motor.

Methods and uses of the type described above are used in the production of electric motors, especially in vehicles.

LIST OF REFERENCE NUMBERS

E

Schweiß-Elektroden

F

Formlitze

H1

Hülse / Kopfende

H2

Hülse / Kopfende

D

Drahtpaket

S

Stator

R

Drehachse

1

isolierter Draht

1'

teilweise abisolierter Draht

2

Umformeinrichtung, insbesondere Wicklungshalter

2.1

erster Finger

2.2

zweiter Finger

2.3

dritter Finger

2.4

vierter Finger

2a

Langseite

2b

Kurzseite

3

Abisoliereinrichtung, insbesondere Laser

4

Verdrilleinrichtung

4.1

erster Greifer

4.2

zweiter Greifer

5

Kompaktiereinrichtung, insbesondere Presse

The following reference numbers are used in the figures:

e

Welding electrodes

F

Formlitze

H1

Sleeve / head end

H2

Sleeve / head end

D

wire package

S

stator

R

axis of rotation

1

insulated wire

1'

partially stripped wire

2

Forming device, in particular winding holder

2.1

first finger

2.2

second finger

2.3

third finger

2.4

fourth finger

2a

long side

2 B

short side

3

Abisoliereinrichtung, in particular laser

4

twisting

4.1

first gripper

4.2

second gripper

5

Compacting device, in particular press

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 9035526 B2 [0003]
• DE 10113831 B4 [0003]
• EP 3051669 A1 [0006]
• DE 102015201711 A1 [0074]

Claims (12)

Method for producing a shaped strand (F) from a straight or substantially straight tapered insulated wire (1), comprising the following method steps: a) forming the insulated wire (1) in at least one half-loop, ring or coil with a forming device (2); b) twisting the at least one half-loop, ring or helix into a wire package (D) with a twisting device (4); c) compacting the wire package (D) with a compacting device (5). Method according to Claim 1 , characterized in that the forming in a designed as a winding holder forming device (2) is carried out, wherein - the winding holder has a finger (2.1) over which the insulated wire is placed and formed into a half-loop, a short side (2b) and two long sides (2a), or - the winding holder has two fingers (2.1, 2.2), wherein the fingers are parallel or substantially parallel to each other and spaced from each other, wherein at least one ring of the insulated wire is pushed onto the winding holder, respectively two short sides (2b) resting against the fingers and two long sides (2a), or - the winding holder having two fingers (2.1, 2.2) and a rotation axis (R), the fingers being aligned parallel or substantially parallel to each other and spaced from each other wherein the insulated wire is wound into a helix on the winding holder, which abuts two on the fingers the short sides (2b) and two long sides (2a), or - the winding holder has four fingers (2.1 to 2.4), wherein the fingers are parallel or substantially parallel to each other and spaced from each other, wherein at least one ring of the insulated wire on the Winding holder is pushed, each having two arranged between the fingers short sides (2b) and two fingers arranged between the long sides (2a), or - the winding holder has four fingers (2.1 to 2.4) and a rotation axis (R), wherein the fingers parallel or are substantially parallel to each other and spaced from each other, wherein the insulated wire is wound into a coil on the winding holder having two arranged between the respective fingers short sides (2b) and two arranged between the fingers long sides (2a). A method according to at least one of the preceding claims, characterized in that a partial stripping of the wire or the half-loop, ring or helix is performed with a Abisoliereinrichtung (3), wherein the partial stripping after the forming (a) and before the twisting (b ), in particular on the long sides (2a) or on the short sides (2b) between fingers of a winding holder, or the partial stripping is carried out before the forming (a), in particular at the straight or substantially straight tapered insulated wire. Method according to at least one of the preceding claims, characterized in that the partial stripping mechanically and / or abrasive, in particular by grinding and / or sandblasting, and / or chemical and / or thermal, in particular using cold brittleness, laser sublimation, induction heating, he follows. Method according to at least one of the preceding claims, characterized in that the twisting of the at least one half-loop, ring or helix is carried out with a twisting device (4), wherein the twisting device in particular a first gripper (4.1) for the first distal end of the at least one half-loop, Ring or coil, and in particular a second gripper (4.2) for the second distal end of the at least one half-loop, ring or coil, wherein the grippers are rotated in particular about or about the longitudinal axis of the at least one half-loop, ring or coil. Method according to at least one of the preceding claims, characterized in that the first gripper is formed by a first finger and the second gripper by a second finger or a pliers tool. Method according to at least one of the preceding claims, characterized in that the twisting device is integrated in the forming device or the twisting is carried out in the forming device. Method according to at least one of the preceding claims, characterized in that the insulated wire and / or the wire package is at least partially acted upon with a baked enamel. Method according to at least one of the preceding claims, characterized in that the stripped wire sections are mechanically and electrically connected to each other after twisting, wherein the connection of the stripped wire sections in the head ends is made in particular without sleeves. Method for producing an electric motor, comprising a stator (S), wherein the winding in the stator is formed at least in sections of stranded wire, characterized in that the shaped strand at least in sections with the method according to at least one of Claims 1 to 8th was produced. Use of stranded wire in the stator (S) of an electric motor, characterized in that it is at least partially in the form of a strand according to the method according to Claim 1 to 8th produced stranded wire (F) is. Formlitze, manufactured after at least one of Claims 1 to 8th , characterized in that at least one head end has non-severed loops.

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